Manufacturing method and dismantling method for plasma display device

ABSTRACT

The manufacturing method and dismantling method of a plasma display device are disclosed. The methods can bond a panel to a holder reliably, and can separate them easily upon scrapping a plasma display device. The manufacturing method comprises the steps of: (a) bonding one of adhesive layers, which are provided on both surfaces of an adhesive sheet consists of porous insulating sheet, to panel holder, to bond rear surface of panel to a holder, and (b) bonding another adhesive layer to rear surface of panel. And the dismantling method comprises the step of separating panel from holder by cutting porous insulating sheet of the adhesive sheet.

TECHNICAL FIELD

[0001] The present invention relates to manufacturing method and dismantling method for scrapping plasma display device known as a technology for large screen with slim and lightweight display.

BACKGROUND ART

[0002] Recently, a plasma display device (thin display panel) has become an attractive subject as a display with excellent visibility and the technology is steadily advancing for large-sized screen with high definition.

[0003] The plasma display devices are roughly divided into AC powered and DC powered in driving method, and surface discharge and counter discharge in discharging method. Currently, however, surface discharge AC powered structure has become a mainstream technology from a stand point of high definition, large screen and simplified manufacturing method.

[0004] In the field of plasma display device technology, an example is disclosed in Japanese Patent No. 2,807,672 to bond panel made of mainly glass and holder made of aluminum and the like with double face adhesive composed of acrylic, urethane or silicone material, or to secure panel and holder via a heat conductive sheet.

[0005] Panel and chassis of plasma display device must be bonded tightly, as panel of plasma display device must never peel off from chassis during use or transportation, and heat generated in panel needs to be conducted toward chassis efficiently. On the other hand, a glass made panel of a plasma display device must necessarily be separated easily off from metal chassis for scrapping and recycling of resources in case of device failure due to some accident.

[0006] However, a panel and a chassis are bonded tightly to prevent possible peeling off and to conduct heat generated in panel through conductive sheet efficiently. Due to the above conventional art, a panel is firstly broken into pieces and then glass pieces left on the chassis must be cleared by scraper or the like to separate a panel from a chassis. The dismantling work, therefore, takes a lot of time and trouble.

[0007] The present invention aims at providing a method enable to separate a panel easily from chassis, serves as a panel holder, to solve the problem.

SUMMARY OF THE INVENTION

[0008] The manufacturing method of a plasma display panel disclosed in this invention aims to bond a panel to a holder to hold a panel, the panel comprises a pair of substrates, in which at least front side of the substrates is transparent, placed facing each other so that a discharge space is formed between the substrates to provide a plurality of discharge cells.

[0009] The method comprises the steps of:

[0010] (a) bonding a holder to the first adhesive layer of adhesive layers provided on both surfaces of a heat conductive porous insulating sheet of an adhesive sheet;

[0011] and

[0012] (b) bonding rear side of said panel to the second adhesive layer of said adhesive sheet.

[0013] This configuration can bond the adhesive sheets to over full surface of panel or holder evenly, and can conduct heat from panel toward holder efficiently.

[0014] The dismantling method of a plasma display device disclosed in this invention aims to separate the panel off from the holder, the panel comprises a pair of substrates, in which at least front side of the substrates is transparent, placed facing each other so that a discharge space is formed between the substrates to provide a plurality of discharge cells.

[0015] Rear surface of the panel and the holder to hold the panel are bonded to adhesive layers provided on both surfaces of a heat conductive porous insulating sheet of an adhesive sheet respectively.

[0016] The method comprises the step of cutting porous insulating sheet of the adhesive sheet to separate the panel off from the holder.

[0017] This configuration can separate a panel, made of mainly glass, from chassis, made of mainly metal, easily by cutting the porous insulating sheet for selecting and recycling of resources in case of scrapping due to device failure or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018]FIG. 1 illustrates a perspective view showing a panel structure of a plasma display device.

[0019]FIG. 2 illustrates a wiring diagram showing a panel electrodes arrangement of a plasma display device.

[0020]FIG. 3 illustrates an exploded perspective view showing an example of a general structure of a plasma display device.

[0021]FIG. 4 illustrates a cross-sectional view showing a structure of an adhesive sheet used in an exemplary embodiment of the present invention.

[0022]FIG. 5 illustrates a partial schematic view showing a manufacturing process of a plasma display device used in an exemplary embodiment of the present invention.

[0023]FIG. 6 illustrates a schematic cross-sectional view showing a configuration of a plasma display device used in other exemplary embodiment of the present invention.

[0024]FIG. 7 illustrates a schematic cross-sectional view showing a dismantling method of a plasma display device used in an exemplary embodiment of the present invention.

[0025]FIG. 8 illustrates a plan view of FIG. 7.

[0026]FIG. 9 illustrates a perspective view showing a dismantling method of a plasma display device used in other exemplary embodiment of the present invention.

[0027]FIG. 10 illustrates a perspective view showing a dismantling method of a plasma display device used in other exemplary embodiment of the present invention.

[0028]FIG. 11 illustrates a perspective view showing a dismantling method of a plasma display device used in other exemplary embodiment of the present invention.

DETAILED DESCRIPTIONS OF THE INVENTION

[0029] The exemplary embodiments of this invention are described with reference to the drawings.

[0030] First, a plasma display device is described using FIGS. 1 to 3.

[0031]FIG. 1 illustrates a perspective view showing a panel structure of a plasma display device.

[0032] A panel has following structures:

[0033] (a) a plurality arrays of display electrodes 2 consist of pairs of scan electrode and sustain electrode formed on transparent front substrate 1;

[0034] (b) dielectric layer 3 formed on the arrays of electrodes to cover;

[0035] (c) protective layer 4 formed on dielectric layer 3 to cover;

[0036] (d) a plurality arrays of stripe shaped address electrodes 7 covered by overcoat layer 6 formed on rear substrate 5 which is placed facing front substrate 1, crossing display electrodes 2 consist of scan electrodes and sustain electrodes;

[0037] (e) a plurality of ribs 8 placed in parallel with address electrodes 7;

[0038] (f) fluorescent layers 9 provided on side walls of ribs 8 and on surfaces of overcoat layer 6;

[0039] (g) substrate 1 and substrate 5 placed facing each other so that display electrodes 2 consist of scan electrodes and sustain electrodes cross address electrodes 7 at approximately right angle, forming tiny discharge spaces between the substrates, and are sealed in surrounding peripheries.

[0040] (h) a discharge space filled with one of rare gases such as Herium, Neon, Argon or Xenon, or a mixture of them as a discharge gas;

[0041] (i) a discharge space divided into a plurality of partitions by ribs 8 creating a plurality of discharge cells where intersection points of display electrodes 2 and address electrodes 7 are located; and

[0042] (j) each discharge cell provided with one of fluorescent layer 9 of red, green and blue in this order.

[0043]FIG. 2 illustrates a wiring diagram showing a panel electrode arrangement of a plasma display device. Pairs of scan electrode and sustain electrode, and address electrodes form an M×N matrix configuration that has scan electrode codes of SCN 1 to SCAN M and sustain electrode codes of SUS 1 to SUS M arranged in line direction and address electrode codes of D 1 to D N arranged in column direction, as shown in FIG. 2.

[0044] In plasma display panel having above electrode configuration, a writing pulse supplied between an address electrode and a scan electrode generates address discharge between address electrode and scan electrode.

[0045] Selecting suitable discharge cells, then a sustaining discharge between scan electrodes and sustain electrodes is produced to provide a prescribed display by applying alternative periodically flipping sustaining pulse on scan electrodes and sustain electrodes.

[0046]FIG. 3 illustrates an exploded perspective view showing an example of a general structure of a plasma display device. In FIG. 3, chassis to house panel 10 consists of front frame 11 and back cover 12 made of metal. Optical filter and front cover 13 made of glass or the like, serves as a protector of panel as well, is disposed at an opening of front frame 11. In addition, front cover 13 is provided with, for example, a silver deposition to shield radiation of unnecessary electromagnetic wave. And additionally, a plurality of vents 12 are provided in back cover 12 to radiate heat generated in panel 10 to outside.

[0047] Panel 10 is bonded to front surface of chassis 14 made of aluminum or the like, serves as a panel holder and a heat radiator as well, via a double face adhesive 15 composed of acrylic, urethane or silicone material, or via an adhesive sheet 15 containing heat conductive material. A plurality of circuit block 16 to drive panel 10 for displaying is mounted on back surface of chassis 14. Adhesive sheet 15 serves to conduct heat generated in panel 10 to chassis 14 for efficient radiation. Circuit block 16 has electrical circuits to drive and control panel 10 for displaying, and whose external terminals provided on peripheries of panel 10 are electrically connected to a plurality of flexible wiring plates (not shown) protruding on all sides of chassis 14.

[0048] Back surface of chassis 14 has bosses 14 a, formed by die casting, for setting circuit block 16 or fixing back cover 12. This chassis 14 can replace aluminum plate with fixed pins.

[0049] Next, a manufacturing method of a plasma display device used in the exemplary embodiment of the present invention is described. FIG. 4 illustrates a cross-sectional view showing a structure of an adhesive sheet used in the exemplary embodiment of the present invention. Adhesive sheet 25 is porous insulating sheet 25 a composed of foams such as urethane foam and the like, on which adhesive layers 25 b and 25 c are applied on both surfaces, as shown in FIG. 4.

[0050] Adhesive layer 25 b to bond to panel has a plurality of slits 25 d provided from surface of adhesive 25 b toward thickness direction of porous insulating sheet 25 a. Slit 25 d having approximate depth to reach intermediate of insulating sheet 25 a can be applied by perforated line with a certain pattern.

[0051] Porous insulating sheet 25 is made of high heat conductive material to increase total heat conductive property of adhesive sheet 25.

[0052]FIG. 5 illustrates a partial schematic view showing a manufacturing process of a plasma display device used in an exemplary embodiment of the present invention. In FIG. 5, panel 21 has a structure having front substrate 22 and rear substrate 23, as shown in FIG. 1

[0053] A plurality arrays of display electrodes are formed on transparent front substrate 22 made of glass plate or the like, and dielectric layer and protective layer are applied to cover these group of electrodes.

[0054] A plurality arrays of address electrodes covered by overcoat layer are formed on rear substrate 23 placed facing front substrate, crossing display electrodes, and a plurality of ribs 8 are placed in parallel with address electrodes to provide fluorescent layers on side walls of the ribs.

[0055] Front substrate 22 and rear substrate 23 are placed facing each other so that display electrodes cross address electrodes at approximately right angle, forming tiny discharge spaces between the substrates, and are sealed in surrounding peripheries.

[0056] The discharge space is filled with one of Herium, Neon, Argon or Xenon, or a mixture of them as a discharge gas to produce a plasma display panel having a plurality of discharge cells where intersection points of display electrodes and address electrodes are located.

[0057] On the other hand, a plurality of circuit block 26 to drive panel for displaying are mounted on back surface of chassis 14, a panel holder made of aluminum or the like and serves as heat radiator at the same time.

[0058] Panel 21 is bonded to front surface of chassis 24, serves as a panel holder, with adhesive sheet 25 serves to conduct heat generated in panel 21 to chassis 24 for efficient radiation.

[0059] Next, a manufacturing method of the plasma display device disclosed in this invention is described with reference to FIG. 5. In this invention, firstly, adhesive sheet 25 is bonded to front surface of chassis 24 such that adhesive layer 25 c side of adhesive sheet 25 faces chassis 24, to bond panel 21 to chassis 24, or a holder, via adhesive sheet 25,

[0060]FIG. 5 (a) shows a method to bond adhesive sheet 25 to chassis 24. Adhesive layer 25 c of adhesive sheet 25 bonds to front surface of chassis 24, placing on table 26 and applying pressure gradually from one side of chassis 24 using pressure roller 27.

[0061] This method can bond adhesive sheet 25 to chassis 24 tightly without any residual air bubble between sheet 25 and chassis 24 as shown in FIG. 5 (b). Additionally, adhesive sheet 25 carries peel-off sheets on adhesive layer 25 b and 25 c like typical double face tape, though not shown in drawings. Pressure should be applied using pressure roller 27 from on top of peel-off sheet.

[0062] Next, as shown in FIG. 5 (c), chassis 24 carrying adhesive sheet 25 is placed on panel 21 for positioning such that adhesive sheet 25 faces panel 21 to bond to panel 21 via adhesive sheet 25 provisionally. Then, in this state of things, pressure is applied on chassis 24 gradually to a prescribed value, and the prescribed pressure is allowed to apply for a given length of time then release the pressure to finish the adhesion of panel 21 and chassis 24 via adhesive sheet 25. FIG. 5 (d) illustrates a view after adhesion.

[0063] Second surface of adhesive sheet 25 carried on chassis 24 can hardly be bonded to panel 21 without any residual air bubble between adhesive sheet 25 and panel 21 using pressure roller 27 and the like to push out air bubbles, as panel 21 is made with rigid material.

[0064] The configuration disclosed in this invention employs adhesive sheet 25, consists of porous insulating sheet provided with adhesive layers 25 b and 25 c on both sides. And adhesive layer 25 b that faces panel 21 is provided with slits 25 d as shown in FIG. 4.

[0065] Residual air left between panel 21 and adhesive sheet 25 diffuses into porous insulating 25 a through slits 25 d and then radiates to outside, when panel 21 and adhesive sheet 25 are pressed after the provisional adhesion. Panel 21, therefore, can be bonded to adhesive sheet 25 tightly, creating enough contact area.

[0066]FIG. 6 illustrates a schematic cross-sectional view showing a configuration of a plasma display device used in another exemplary embodiment of the present invention.

[0067] As shown in FIG. 6, adhesive sheet 25 provides adhesive layer 25 c side with slits 25 e additionally. The configuration enables to bond adhesive sheet 25 and chassis 24 also with enough contact area without any residual air bubble between adhesive sheet 25 and chassis 24. In such a case as to provide slits 25 d and 25 e on both sides of adhesive sheet 25, positions of slit 25 d and 25 e are preferably be shifted each other. Needless to say, bore holes instead of slits can affect similarly.

[0068] Next, a dismantling method of a plasma display device manufactured according to aforementioned method is described to separate into panel, mainly composed of glass material, and chassis, serves as a holder and mainly composed of metallic material, in case of scrapping due to failure.

[0069]FIG. 7 illustrates a schematic cross-sectional view showing a dismantling method of a plasma display device used in an exemplary embodiment of the present invention. And FIG. 8 illustrates a plan view of FIG. 7. As shown in FIGS. 7 and 8, a plasma display device disclosed in this invention comprises: (a) panel 21 having a plurality of discharge micro cells; (b) metal chassis 24 to hold panel 21; and (c) adhesive sheet 25 to bond rear surface of panel 21 and front surface of chassis 24, wherein adhesive sheet 25 consists of heat conductive porous insulating sheet 25 a having adhesive layers 25 b and 25 c provided on both surfaces of insulating sheet 25 a. Panel 21 can be easily separated from chassis 24 for dismantling by cutting a portion of porous insulating sheet 25 a of adhesive sheet 25 using, for example, metal cutting wire 28 or the like.

[0070] Cutting wire 28 to serve as a cutting tool has a length longer than long side or short side of panel 21. Cutting wire 28 tugged to show no sagging can cut insulating sheet when moved to cut a portion of insulating sheet 25 a of adhesive sheet 25 from one side of panel 21 as shown in FIGS. 7 and 8. A tape shaped metal cutting tool can replace cutting wire 28 used in FIGS. 7 and 8. Additionally, sliding back and forth a wire like jig saw having saw tooth or a metal tape, inserted between panel 21 and chassis 24, or a rotary cutting tool like a rotary saw may carry out the purpose.

[0071] As mentioned above, the invention disclosed employs adhesive sheet 25 consists of heat conductive porous insulating sheet 25 a provided with adhesive layer 25 b and 25 c on both sides of the insulating sheet to bond panel 21 and chassis 24. As porous insulating sheet 25 contains great many tiny cavities, the sheet can be cut easily by a cutting tool such as cutting wire or the like inserted in the sheet.

[0072] Consequently, panel 21 can be separated from chassis 24 easily within a shorter time than conventional arts.

[0073] FIGS. 9 10 and 11 illustrates a schematic perspective view showing a dismantling method of a plasma display device used in other exemplary embodiments of the present invention.

[0074] FIGS. 9 (a) and (b), and FIGS. 10 (a) and (b) illustrate example cases showing cutting wire 28 inserted between panel 21 and chassis 24. FIGS. 9 (a) and (b) show an example in which cutting wire 28 is inserted between panel 21 and chassis 24 using guiding wire 29. Generally, panel 21 has a plurality of tip-off tubes 21 a to exhaust inner discharge space, to fill discharge gases or to dose getter materials. And, chassis 24 has through holes 24 a such that through holes 24 a do not touch corresponding tip-off tubes 21 a of panel 21.

[0075] In examples shown in FIG. 9 (a) and (b), pulled out portion of guiding wire 29 run through between panel 21 and chassis 24 and pulled out of edge using through holes 24 a is used to insert cutting wire 28 between panel 21 and chassis 24. Cutting wire 28 is guided such that cutting wire 28 does not touch tip-off tubes 21 a, and can cut porous insulating sheet 25 a of adhesive sheet 25 smoothly.

[0076] FIGS. 10 (a) and (b) illuminate an example in which a tape shaped metal plate 28 a is coupled to an end of cutting wire 28 to insert cutting wire between panel 21 and chassis 24 more easily. Inserted metal plate 28 a can guide cutting wire 28 to enter between panel 21 and chassis 24.

[0077]FIG. 11 illustrates another example in which porous insulating sheet 25 a of heat conductive sheet 25 between panel 21 and chassis 24 is cut using another cutting wire 30 equipped with rollers 30 a.

[0078] Cutting wire 30 can keep approximately central positioning in thickness direction in insulating sheet 25 a without meandering, as rollers 30 a roll while contacting inner surfaces of panel 21 and chassis 24 when cutting wire 30 moves inside of porous insulating sheet 25 a of adhesive sheet 25. Moreover, as friction resistance due to touching of cutting wire to adhesive layer 25 b or 25 c in case of other cutting wire is reduced, cutting wire 30 can cut porous insulating sheet 25 a of heat conductive sheet 25 smoothly.

[0079] As is clear from the above, according to the manufacturing method disclosed in the invention, the plasma display device has such a configuration that panel and holder are bonded via an adhesive sheet to provide with enough contact area. Moreover, panel and holder can be dismantled easily to contribute to efficient recycling of materials for plasma display devices. 

1. A manufacturing method of plasma display device comprising the steps of: (a) bonding a holder to the first adhesive layer of adhesive layers provided on both surfaces of a heat conductive porous insulating sheet of an adhesive sheet; and (b) bonding rear side of said panel to the second adhesive layer of said adhesive sheet, to bond a panel to a holder to hold a panel, the panel comprises a pair of substrates, in which at least front side of the substrates is transparent, placed facing each other so that a discharge space is formed between the substrates to provide a plurality of discharge cells.
 2. The manufacturing method of plasma display device of claim 1, wherein adhesive sheet has a plurality of slits provided at least from surface, facing panel, toward thickness direction of porous insulating sheet.
 3. A dismantling method of plasma display device comprising the step of: (a) cutting porous insulating sheet of said adhesive sheet to separate said panel off from said holder, the panel comprises a pair of substrates, in which at least front side of the substrates is transparent, placed facing each other so that a discharge space is formed between the substrates to provide a plurality of discharge cells, wherein rear surface and holder to hold said panel are bonded to adhesive layers provided on both surfaces of a heat conductive porous insulating sheet of an adhesive sheet respectively.
 4. The dismantling method of plasma display device of claim 3, wherein porous insulating sheet of said adhesive sheet is cut through using a cutting tool having dimensions of longer than long side or short side of said panel. 